brewery tank controls

[jwrehm]

Hello all -

I'm looking to develop a system for controlling the Fermentation tanks in our brewery using LabView controls.  We currently use the standard tempermental fuzzy logic PID microcontrolers (Partlow, Watlow, etc).  I believe these are overly expensive for the functionality they provide, and being a both a professional Brewer and a LabView/systems guy I am always seeking better ways to control the process.  Programatically, I realize all the flexible advantages LabView would have for our system, however I'm evaluating the feasibility ( on a cost basis) of replacing these with a custom LabView controlled system.

Our current process:  A type K thermocouple monitors the tank temperature via the fuzzy logic controller.  The controller's alarm relay (rated 5 amps at 110 VAC) responds based on a setpoint and will either send coolant thru the jacketed tank or not. The controller alarm relay activates a seperate solid state relay (20 mA) which then sends an electrical signal to a circulating pump (single phase, 115 Volt, ranging 0.5-2.0 amps) and a solenoid valve (120 Volt coil) with their own power sources. 

We currently use this system as an on/off controller.  The tanks are either cooling or not - and control beyond that is manual.  I realize that soaking, ramping, and other functions can be set with these controllers but not only do we have numerous controller brands with different parameters, but the programming is beyond the scope of many of the people that operate the system.  I'm looking to build in user friendly functionality and operate all the tank controls from one central computer hub.

So the question is, how do I replace the controllers and wire for LabView control of the motors and solenoids?  Is the solution to just run wires to a big Data Acquisition board connected to a central computer? Or is building a wireless network of tanks feasible? (My budget will be relatively small)  We've got 14 tanks to control spaced evenly over about 4,000 sq. ft. Any idea's, experience, hardware suggestions, etc. - I'd love to hear.  Thanks in advance for all your help!

- John Rehm
Brewer in Chief, Philadelphia Brewing Co.
LabView Instructor, La Salle University

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From McMaster Carr supply (www.mcmastercarr.com):

Autotuning P-I-D Temperature Controllers
1/16 DIN	These autotuning controllers with fuzzy logic calculate the optimal P-I-D (Proportional-Integral-Derivative) parameters for a particular process and store them in memory for future use. Controllers accept input from RTDs and thermocouple types J (-58° to +1832°  F/-50° to +1000°  C), K (-58° to +2498°  F/-50° to +1370°  C), and T (-454° to +752°  F/-270° to +400°  C). Units are easy to program using menu and keypad. Each has selectable auto/manual control modes, two limit alarm relays with eight programmable modes, and ramp/soak programming ("ramp" for length of time to reach a temperature and "soak" for length of time a temperature is maintained).    Controllers are ° F/° C selectable, and dual LED displays show present temperature and setpoint simultaneously. Top LED is red, and bottom LED is green. Units accept probes with bare lead wires (probes sold separately). Operate on 90 to 264 VAC. All include screw terminal connections and mounting brackets. Accuracy is ±0.36°  F (±0.2°  C) for RTDs and ±1.8°  F (±1°  C) for thermocouples. CE approved.     1/16 DIN size units have one control and two alarm relays with SPST contacts that are wired normally open and rated 5 amps at 110 VAC. Top LED is  3/8" high, and bottom LED is  5/16" high.     1/4 DIN size units have two control and two alarm relays with SPST contacts that are wired normally open and rated 5 amps at 110 VAC. Top LED is  9/16" high, and bottom LED is  3/8" high.

[Matthew_Williams]

Hi John.  A couple of suggestions:

1) If there is any way to remotely program your existing controllers, building your system on them may
have several advantages.  Lets you use your existing hardware and wiring, reduces new stuff to buy,
and gives you a fall-back position if problems crop up with the master controller.  Also can be
implemented in stages, a few tanks at a time.

2) Replacing your existing controllers with remotely programmable ones still gives you the other advantages
of the architecture above, just you have to buy new controllers.

3) Fieldpoint hardware is certainly capable of doing what you want, and gives you independence from
a PC, i.e. you can download your process parameters to the Fieldpoint controller and disconnect the
PC, or leave it running as a monitor.  Gives you the reliability of an industrial controller with the option
of a PC GUI.  You could run all 14 tanks with one controller.

For a 4000 ft^2 facility, I wouldn't expect wireless to be worth the trouble unless there are other
considerations like mobile equipment.

I am in Jenkintown.  I'd be happy to trade tips for a tour.  Are you involved with the ISBT program?

Matt

[Wayne.C]

Wow, a professional brewer and LabView guy.  My hero! 

I can't think of any hardware solutions that are better than Matt's.   I would just add a couple of features that you might want to consider.  First is the ability to remotely monitor/control your process from offsite.  Second would be the ability to send an alarm in the case of a major malfunction.

[Ben]

Centerbolt posted;

"  I would just add a couple of features that you might want to consider.  First is the ability to remotely monitor/control your process from offsite.  Second would be the ability to send an alarm in the case of a major malfunction."

Don't worry I am sure Matt can handle those options as well as throwing in a little 21-CFR-11 complience while he is at it.

Ben

[Wayne.C]

Ben,

The alarm I was most worried about was Matt sneaking in after hours for a "quick tour". 

[Matthew_Williams]

Development notes:
add after-hours maintenance alarm override

🙂

Matt

[jwrehm]

Matt - Thanks so much for the advice.  I like the idea of building upon the existing controllers/system that we have.  I don't have much experience with the Fieldpoint hardware but just from checking it out it looks like exactly what we need.  We're expanding and bringing 10 new tanks online soon so I'll have to see if I can work the hardware into the budget.  I'm assuming like most things LabView the Fieldpoint hardware is user friendly and easy to program (correct me if I'm wrong!).

It would be very nice to have remote access to the data as well.

I do currently teach as a part time Instructor in the ISBT Program at La Salle though I am a full time Brewer. What a great program!  They/we are doing some amazing things.

If you ever want to come down to the brewery I'd love to chat and show you around - just let me know.  That goes for anyone who wants to talk LabView and/or beer with me.  Plenty of free samples!

Thanks again.

-John
john@philadelphiabrewing.com

[Wayne.C]

Ben,

Did you tell your boss about that really important NI Seminar in Philly yet?  

[Matthew_Williams]

Queue for the seminar forms right here, please have your tickets ready.

I'll second John's comments about ISBT; if anybody knows a young'n interested
in tech/bio/business, it is well worth a look.

Matt

[Ben]

Centerbolt asked;

"

Ben,

Did you tell your boss about that really important NI Seminar in Philly yet?  

"

NI Seminar? You think they let me go to to NI Seminars? Hardly! We have sales people that attend those. I suspect they learned a leason some years ago when the put me in sales to do cold-calling. I never did find any buisness but I did help out a number of LabVIEW users who's last name started with "A".

Ever since then they have kept me hidden in the back corner and don't let me talk to anyone that doesn't have a purchase order.

Ben